Heated Cabinets
Copyright July 2017 Future Products Group Limited. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Future Products Group Ltd. Part No. 26121 Rev. D July 2017-2 - 4000 Series Cabinets
Table of Contents INTRODUCTION... 6 Welcome... 6 Future Products Group (FPG)... 6 Guidance and Help... 6 Warranty... 6 Warranty Period... 6 Liability Exceptions... 7 Specific Exclusions... 7 Assessment... 7 Time Limit... 7 Caution... 7 OPERATION... 8 Cabinet Layout... 8 4000 Series Cabinets... 8 Lighting... 8 Controls... 8 Light Switch... 8 Heating... 8 Thermometer... 8 Preparation... 9 Shelf Location and Ticketing... 9 Shelf Adjustment... 9 Power Supply... 9 Set the Temperature... 9 Fumes and Odours... 9 Load Cabinet... 10 WARNING: Aluminium Foil... 10 Close all Doors... 10 Turn on Lights... 10 Door Opening... 10 TROUBLE SHOOTING... 11 CLEANING... 12 Cautions... 12 Power... 12 Water... 12 Exterior... 12 Metal Surfaces... 12 Glass... 12 Sliding Doors... 12 IN 4H 08/12/15-3 - Future Products Group
Interior... 13 Cabinet Well... 13 Trays, Racks, Shelves & Air Grills... 13 Routines... 13 Schedules... 13 Inspection... 13 Correction... 13 INSTALLATION... 14 Regulations... 14 Compliance with Local Requirements... 14 Setting Up... 14 Unpacking... 14 Site Preparation... 14 Cabinet Preparation... 14 Shelf Trays... 14 Grounding... 15 Power Supply... 15 Isolation... 15 Location... 15 Ventilation... 15 Access... 15 Fumes and Odours... 15 Livery... 16 Custom Inserts... 16 SERVICING... 17 Control Gear... 17 Location... 17 Lighting... 17 Caution... 17 Test Lighting Components... 17 Access to LED Strips... 17 LED Strip Replacement... 17 Heating... 18 Caution... 18 Element Replacement... 18 Test... 18 Caution... 18 Re-assemble... 18 Door Seals... 19 Seal Replacement... 19 Sliding Doors... 19 Mains Lead... 19 Lead Replacement... 19 Part No. 26121 Rev. D July 2017-4 - 4000 Series Cabinets
SPECIFICATIONS... 20 Mechanical... 20 Electrical... 20 Compliance... 21 Safety Aspects... 21 Performance Aspects... 21 Improvements... 21 Ongoing Development... 21 ELECTRICAL CIRCUIT DIAGRAMS... 22 Model: IN 4H08... 22 Model: IN 4H12... 22 Model: IN 4H15... 23 SPARE PARTS... 24 Cabinet Serial Number... 24 Location of Glass Parts... 25 MECHANICAL DRAWINGS... 26 Dimensions... 26 IN-4H08/12/15... 26 Cabinet Variants... 27 Livery... 27 IN 4H 08/12/15-5 - Future Products Group
INTRODUCTION Welcome HEATED CABINETS - INTRODUCTION Future Products Group (FPG) Welcome to the world of FPG! Our products are designed and engineered to give you the optimal performance that you deserve with innovative visual merchandising appeal. We are confident that you will be delighted with your state of the art inline food service cabinet, and that it will become a valued appliance in your store. Guidance and Help Any new appliance can seem very complex and confusing at first glance. To ensure you receive the utmost benefit from your new inline cabinet, there are two things you can do. Before operating the cabinet, please read the instruction book carefully and follow its recommendations. The time taken will be well spent. These instructions both general and technical tell you how to install, operate and look after your inline food service cabinet so that you can receive the full benefits that this cabinet has to offer. These instructions cannot, however, cover all eventualities. If you are unsure of any aspect of the installation, instructions or performance of your cabinet, contact your dealer promptly or contact us via email to support@fpgworld.com. Warranty HEATED CABINETS - INTRODUCTION Warranty Period Future Products Group Limited warrants, to the original purchaser of an FPG manufactured food service cabinet that for ONE YEAR (12 months), from the date of purchase, any defect in workmanship or material resulting in the product malfunctioning while under correct use will be rectified. Liability under this warranty is limited to replacing or repairing a part, without charge. Continued on next page Part No. 26121 Rev. D July 2017-6 - 4000 Series Cabinets
Warranty cont. HEATED CABINETS - INTRODUCTION Liability Exceptions Liability under this warranty does not include: Any loss, or damage or expenses directly or indirectly arising from use or inability to use the product or from any other cause. Any part of the cabinet which has been subject to misuse, neglect, alteration, incorrect installation, accident, or damage caused by transportation, use of abrasive or caustic chemicals, flooding, fire or acts of God. Any damage or malfunction resulting from the use of non-fpg supplied spare parts. Specific Exclusions The following are specifically excluded from warranty: Breakage of glass or plastic components or the replacement of LED lighting strips or gaskets. Failure to re-assemble the cabinet correctly after cleaning. Fair wear and tear. Assessment The liability under this warranty is dependent on an assessment by FPG, to determine the defect in workmanship or materials. Time Limit FPG does not guarantee that any service to be performed under this warranty will be carried out within any particular time limit. Caution No warranty claim will be accepted unless authorised by FPG prior to commencement of service. IN 4H 08/12/15-7 - Future Products Group
OPERATION Cabinet Layout HEATED CABINETS - OPERATION 4000 Series Cabinets The 4000 Series cabinets are available with either fixed glass or sliding glass front doors, and sliding glass rear doors. The series includes Ambient, Heated and Refrigerated models. The cabinet lighting and temperature controls are on the back of the cabinet. Lighting All cabinets are fitted with high efficiency LED lighting strips in the ceiling of the cabinet and below each shelf as standard. Controls HEATED CABINETS - OPERATION Light Switch The control panel is located at the top of the cabinet back. To turn the lights on, rotate the switch, with the LIGHT symbol. Heating Set the desired temperature with the thermostat control knob. Thermometer A thermometer indicates the internal temperature of the cabinet. Part No. 26121 Rev. D July 2017-8 - 4000 Series Cabinets
Preparation HEATED CABINETS - OPERATION Shelf Location and Ticketing All shelves are adjustable in height and can easily be moved up or down, to match product size. The movement is restricted to 50mm, because of the electric cables to the lights. For greater movement contact the manufacturer or supplier for advice, as electrical modifications may be required. Wire shelf racks are supplied as standard, but trays, as shown, are available to order. The front and rear edges of the shelves are profiled to carry ticketing/labels. Shelf Adjustment To move the shelf brackets, first remove the sliding doors and the shelf trays. Using two people, one on each bracket, lift the brackets straight up firmly and then pull the brackets forward, to disengage them from the slots in the support posts. Insert the brackets into their new position, and push bracket down firmly. The brackets may be positioned to give two different degrees of slope to the shelves. Refit all shelf trays and doors. N.B. Make sure brackets are pushed down as far as they can go. Failure to do this may result in shelf collapse, when loaded with product. Power Supply Ensure that power is connected to the cabinet. Set the Temperature Set the thermostat to the desired temperature, 75 degrees Celsius is the recommended setting to maintain food temperature within food safety guidelines. NOTE Setting the dial to a higher temperature than required will not speed up the heating process. Set it to the desired temperature. Fumes and Odours Before use, operate the cabinet for 4 hours to remove any fumes or odours, which may be present. This will avoid possible tainting of food. Continued on next page IN 4H 08/12/15-9 - Future Products Group
Preparation cont. HEATED CABINETS - OPERATION Load Cabinet Load the cabinet with pre-heated product. The cabinet is designed to maintain the temperature of pre-heated product above 65 C. It is not an oven, and consequently, if cold product is introduced, there could be a considerable delay before the operating temperature rises to the normal operating level. WARNING: Aluminium Foil Do NOT place aluminium foil on the base trays. This will disrupt the convection circulation of air, and cause uneven heating. Blockage of air vents may cause severe overheating of the cabinet base. Close all Doors It is important to keep all cabinet doors closed. If doors are not fully closed, an even temperature will not be maintained within the cabinet. Turn on Lights When ready for service, turn on the cabinet lights. Door Opening The cabinet is designed to maintain food at a temperature above 65 C. The heating system is designed to maintain this temperature with the doors being opened and closed up to sixty times per hour. If the doors are left open for an extended period the temperature will fall. Once the doors are closed the temperature will take some time to rise to the normal operating level. The longer the doors are open the longer the time to restore normal operating temperature. Part No. 26121 Rev. D July 2017-10 - 4000 Series Cabinets
TROUBLE SHOOTING FAULT POSSIBLE CAUSE REMEDY Doors are not sliding smoothly Cabinet does not operate/start Cabinet does not reach temperature Cabinet lights not working Door not in track Debris in track Lack of lubricant The mains isolating switch on the wall, circuit breaker or fuses are off at the power board The thermostat is in the OFF position Internal fuse blown One or more doors is open Thermostat setting disturbed Thermostat is faulty An element is blown The light switch is OFF A failed LED power supply An LED strip has failed Internal fuse blown Install door correctly in track Clean door tracks (see cleaning) Apply food grade lubricant to door track Turn isolating switch circuit breaker or fuses on Turn control knob to desired temperature Have wiring checked and replace fuse (5A Slow Blow) Close doors and re-test temperature after thirty minutes Re-set thermostat and re-test after thirty minutes Have thermostat replaced Have the element replaced Turn light switch ON Replace the power supply Replace the LED assembly Have wiring checked and replace fuse (5A Slow Blow) Aluminium parts corroded Caustic detergent damage Order replacement parts Service Personnel Only The table entries in italics indicate actions to be taken only by qualified Service Personnel. IN 4H 08/12/15-11 - Future Products Group
CLEANING Cautions HEATED CABINETS - CLEANING Power ALWAYS TURN THE POWER SUPPLY OFF BEFORE CLEANING. Water THIS UNIT IS NOT WATERPROOF. DO NOT USE A WATER JET SPRAY TO CLEAN THE INTERIOR OR EXTERIOR OF THIS CABINET. Exterior HEATED CABINETS - CLEANING Metal Surfaces Stainless steel or aluminium surfaces should be cleaned with hot soapy water or a good quality metal cleaning compound. DO NOT clean surfaces with abrasive pads or cleaners (e.g. Scotchbrite pads or Jif), as paint, stainless steel and aluminium surfaces will be damaged. Glass All glass should be cleaned using a good quality glass cleaner and a clean cloth. DO NOT use abrasive pads or cleaners, because they will damage the surface of the glass. Sliding Doors Sliding glass doors are located by plastic guides at the top and bottom. The doors can be removed for cleaning by sliding the door to central position, placing hands either side of the door, lifting it up and then swinging it out at the bottom. When replacing doors, make sure that they are located in the correct slots, top and bottom. The left door should be in the inner slots, and the right door in the outer slots. Sliding door tracks should be vacuumed out regularly to keep doors sliding freely. Continued on next page Part No. 26121 Rev. D July 2017-12 - 4000 Series Cabinets
Interior HEATED CABINETS - CLEANING Cabinet Well To clean the hot cabinet well, first lift out the deck trays and dividers and then sweep out or vacuum away loose debris. This cabinet is a dry well unit, so the well is not waterproof. Do NOT pour water into the well as it will leak out and damage insulation and electrical wiring. Trays, Racks, Shelves & Air Grills Stainless steel trays, racks, shelves, grills etc. should be cleaned with hot soapy water. Do not use abrasive pads or cleaners (e.g. Scotchbrite pads or Jif), as these may damage surfaces. Warning: Dishwasher detergents will damage any anodised aluminium parts. Routines HEATED CABINETS - CLEANING Schedules To maintain optimum performance, cleaning schedules must be regular and thorough. Inspection As part of the cleaning routine, the controls, mechanical parts and electrical wiring should be inspected for damage, deterioration or need of adjustment. Correction If any small faults are found, have them attended to promptly by a competent serviceman. Don t wait until they cause a complete breakdown. IN 4H 08/12/15-13 - Future Products Group
INSTALLATION Regulations HEATED CABINETS - INSTALLATION Compliance with Local Requirements It is very important that your inline food cabinet is installed correctly and that the operation is correct before use. Installation must comply with local electrical, health & safety and hygiene requirements. Setting Up HEATED CABINETS - INSTALLATION Unpacking Unpack and check unit for damage and report any damage to the carrier and supplier. Report any deficiencies to your supplier. The cabinet is supplied fully assembled, but the shelf trays are packed separately. Site Preparation Ensure the cabinet location and any bench cut outs are made to the precise measurements shown in the Mechanical Drawings. Position the cabinet in its allocated working position. Use a spirit level to ensure the cabinet is level from side to side and front to back. (If this is not carried out, uneven temperature distribution could occur). Cabinet Preparation Remove all tapes, ties and packers, used to prevent movement during transit. Lift out the deck trays, grills and divider bars, to gain access to the cabinet well. Check that all plastic film protection has been removed from surfaces; otherwise it will melt when the cabinet heats up. Re-assemble the trays and shelves. Shelf Trays Remove the shelf trays from their packing, peel off the protective plastic coating and assemble them on the support members. Continued on next page Part No. 26121 Rev. D July 2017-14 - 4000 Series Cabinets
Setting Up cont. HEATED CABINETS - INSTALLATION Grounding WARNING: THIS APPLIANCE MUST BE GROUNDED TO EARTH The grounding lead, in the mains cable, must always be connected to ground. Terminals are also provided, to allow the cabinet to be bonded to a surge grounding conductor or to adjacent equipment. Power Supply Before connecting to the power supply, check that the local supply is correct to that shown on the rating plate, located on the rear of the cabinet. Isolation If the cabinet is not connected by a plug and socket, but is hard wired to the mains supply, a means of isolation must be provided. If a plug and socket are used, they should still be accessible after the cabinet is installed. Location HEATED CABINETS - INSTALLATION Ventilation The heated cabinet is designed to meet the HACCP specification with free room air circulation. Access Access to the back of the cabinet is required for loading, cleaning, re-positioning of shelves and operation of the control panel. Fumes and Odours Before use, operate the cabinet for 4 hours at 90 C, to remove any fumes or odours, which may be present. Open the doors periodically during this period, to allow a change of air. This will avoid possible tainting of food. IN 4H 08/12/15-15 - Future Products Group
Livery HEATED CABINETS - INSTALLATION Custom Inserts The silver anodised extrusions incorporate grooves, which allow appropriately coloured or printed strips of decorative laminate to be inserted. The strips are held captive by the cabinet ends. The top strips can be easily slid upwards into the top groove, and then down into the bottom one. The lower strip is held captive by the cabinet ends, and has to be bowed for removal and insertion. Insert the upper edge into the narrow groove, closest to the curved surface, bow the strip to insert the end into the lower groove, then, use your thumbs to work the rest of the strip into place. If the strip is hard to bend, a length of wooden dowel can be placed underneath to aid bowing. The dowel should be progressively withdrawn as the strip is inserted. Note: Most metals are too rigid for insertion in this position. Maximum strip thickness is 0.75mm. See Mechanical Drawings for dimensions. Part No. 26121 Rev. D July 2017-16 - 4000 Series Cabinets
SERVICING Control Gear HEATED CABINETS - SERVICING Location The electrical control gear is located in the top of the cabinet. Remove the top plate to access the control gear. The chassis has a light switch, power supplies for the lights, a thermostat, a thermometer and a protective fuse. Lighting HEATED CABINETS - SERVICING Caution Do not service lights without isolating the cabinet from the mains supply. Test Lighting Components Before replacing an LED strip, check that the power supply is working. If there is no dc voltage at the output, the power supply should be replaced. If there is a dc output, the LED strip must be replaced. Access to LED Strips The LED strips are protected with plastic covers. These clip into grooves in the aluminium extrusion. Remove the plastic cover to access the LED strip. The top light assembly is similar to the shelf lights, but the correct replacement unit must be used. LED Strip Replacement Individual LED modules cannot be replaced. A complete light unit must be used. Connection is made with a plug and socket. Disconnect the supply lead from the faulty unit, and reconnect it to the replacement unit. Replace the plastic cover. IN 4H 08/12/15-17 - Future Products Group
Heating HEATED CABINETS - SERVICING Caution DO NOT attempt to replace heating elements without isolating the cabinet at the supply switch or by unplugging it from the mains supply. Element Replacement CAUTION: This must only be carried out by a qualified service person. Remove all base trays and dividers from inside the cabinet, to reveal the heating elements. To access the element terminals, remove the screws securing the element to the rear bulkhead. Unclip the element from its support brackets and withdraw it to reveal the connections. Disconnect the old element, connect the replacement, taking care to replace and refit any insulation material. Position the new element against the bulkhead, clip it into the support brackets and replace the two fixing screws. Test Turn the power on and test the heater operation. If normal operation cannot be restored, by replacing the element, other circuit elements will have to be checked, see Fault Finding. Caution Do not run the cabinet heaters for extended periods, without the base trays and divider bars in position. Directly radiated heat may otherwise damage the lower light fittings. Re-assemble If the heater is now working, re-assemble the base trays and dividers inside the cabinet. Part No. 26121 Rev. D July 2017-18 - 4000 Series Cabinets
Door Seals HEATED CABINETS - SERVICING Seal Replacement The doors should be removed to allow the old seals to be removed and the new ones fitted. See the Cleaning section for details. Sliding Doors Each sliding door has a seal between the door and the cabinet end panel. The seal slides into a groove in the door extrusion, and can be withdrawn and replaced, if damaged. A centre seal is fitted between the inner and outer doors. The Qlon seal is located in a slot in the aluminium extrusion, and can be replaced if damaged. Mains Lead HEATED CABINETS - SERVICING Lead Replacement If damaged, the mains lead must ONLY be replaced by a qualified service person. IN 4H 08/12/15-19 - Future Products Group
SPECIFICATIONS Mechanical HEATED CABINETS - SPECIFICATIONS CABINET MODEL IN 4H08 IN 4H12 IN 4H15 Height 1405 mm 1405 mm 1405 mm Width 803 mm 1203 mm 1503 mm Depth 774 mm 774 mm 774 mm Dry Weight 107 kg 140 kg 170 kg Cabinet Well Material Stainless steel Stainless steel Stainless steel Cabinet Colour Grey and natural anodised aluminium. Grey and natural anodised aluminium. Grey and natural anodised aluminium. Top Lighting Standard Standard Standard Shelf Lighting Standard Standard Standard Glass Type (front/back) Single glazed Single glazed Single glazed Glass Type (ends) Double glazed Double glazed Double glazed Front Doors Sliding or Fixed options Sliding or Fixed options Sliding or Fixed options Number of Shelves Three plus base Three plus base Three plus base Shelf Display Area 0.8 m 2 plus base 0.4 m 2 1.2 m 2 plus base 0.6 m 2 1.6 m 2 Climatic Class & IP plus base 0.8 m 2 All cabinets are suitable for class N climates and have an IP 22 rating Electrical HEATED CABINETS - SPECIFICATIONS CABINET MODEL IN 4H08 IN 4H12 IN 4H15 Voltage 220-240 V 50 Hz 1 220-240 V 50 Hz 1 220-240 V 50 Hz 1 Power 1.6 kw 1.7 kw 3.2 kw Current 6.9 A 7.4 A 13.9 A Connection 3 pin plug, 10 A lead 3 pin plug, 10 A lead 3 pin plug, 15 A lead HACCP Temp. Range 65-80 C 65-80 C 65-80 C Max. Temp. Range 30-90 C 30-90 C 30-90 C Lighting 4 x LED strips 4 x LED strips 4 x LED strips Part No. 26121 Rev. D July 2017-20 - 4000 Series Cabinets
Compliance HEATED CABINETS - SPECIFICATIONS Safety Aspects This cabinet has been designed to comply with the relevant requirements of the following specifications: AS/NZS 3100 : General Requirements for Electrical Equipment IEC 335: Heated Food Cabinets AS/NZS 3820 : Essential Safety Requirements AS/NZS 4417 : Marking of Electrical Products Performance Aspects The cabinet is HACCP compliant, with the following performance: Cabinet Operating Temperature >65 C Test Conditions 23 C Ambient with 60% RH Improvements HEATED CABINETS - SPECIFICATIONS Ongoing Development FPG reserves the right to change specifications and construction, as part of ongoing product improvement. IN 4H 08/12/15-21 - Future Products Group
ELECTRICAL CIRCUIT DIAGRAMS Model: IN 4H08 Inline 4000 Series, 800mm Heated Cabinet Model: IN 4H12 Inline 4000 Series, 1200mm Heated Cabinet Part No. 26121 Rev. D July 2017-22 - 4000 Series Cabinets
ELECTRICAL WIRING DIAGRAMS, Continued Model: IN 4H15 Inline 4000 Series, 1500mm Heated Cabinet IN 4H 08/12/15-23 - Future Products Group
SPARE PARTS Cabinet Serial Number When ordering spare parts, it is important to quote the Serial Number printed on the label fixed to the control panel. This serial number will enable FPG to trace details of the build specification of your particular cabinet, and hence ensure that spare parts are fully compatible. To satisfy warranty conditions, and ensure optimum performance, use only FPG supplied spare parts. Part Description FPG Part No. Light Switch EGO 14372 Knob (light switch) 14374 Knob (thermostat, (30-90 C) 21113 Thermostat 21112 Thermometer 11925 Fuse Link (5A, 250V, Slow Blow) 13330 24V 60W LED power supply 21613 36V 100W LED power supply 25922 LED Driver 700mA 25762 Ant-surge Thermistor 10 Ohm 3A 22354 Polycarbonate Light Cover 1120mm 18113 Polycarbonate Light Cover 720mm 18114 Top Light Replacement Kit for 4H08 69871 Shelf Light Replacement Kit for 4H08 69839 Top Light Replacement Kit for 4H12 69858 Shelf Light Replacement Kit for 4H12 69869 Top Light Replacement Kit for 4H15 69863 Shelf Light Replacement Kit for 4H15 69424 Extraction fan 119mm 230V 21614 Heating Element 1500W 25917 Heating Element 1600W 18683 Qlon centre door seal 13677 Slide-in rubber door seal 11424 Part No. 26121 Rev. D July 2017-24 - 4000 Series Cabinets
SPARE PARTS Continued Location of Glass Parts In the following table, handed glass parts are labelled as viewed from the REAR of the cabinet. Part Description FPG Part No. Double Glazed End Glass Kit LH 62676 Double Glazed End Glass Kit RH 62678 Back Inner Sliding Door(800 cabinets only) 62370 Back Outer Sliding Door(800 cabinets only) 62371 Back Inner Sliding Door(1200 cabinets only) 62372 Back Outer Sliding Door(1200 cabinets only) 62373 Back Inner Sliding Door(1500 cabinets only) 62374 Back Outer Sliding Door(1500 cabinets only) 62375 Front Inner Curved Sliding Door (800 cabinets) 62364 Front Outer Curved Sliding Door (800 cabinets) 62365 Front Inner Curved Sliding Door (1200 cabinets) 62366 Front Outer Curved Sliding Door (1200 cabinets) 62367 Front Inner Curved Sliding Door (1500 cabinets) 62368 Front Outer Curved Sliding Door (1500 cabinets) 62369 Front Curved Fixed Glass Kit (800 cabinets) 62389 Front Curved Fixed Glass Kit (1200 cabinets) 62390 Front Curved Fixed Glass Kit (1500 cabinets) 62391 Product Manual for Inline 4000 Series Heated Cabinets 15873 IN 4H 08/12/15-25 - Future Products Group
Dimensions HEATED CABINETS - MECHANICAL DRAWINGS MECHANICAL DRAWINGS IN-4H08/12/15 Part No. 26121 Rev. D July 2017-26 - 4000 Series Cabinets
Dimensions cont. HEATED CABINETS - MECHANICAL DRAWINGS Cabinet Variants The drawings show the common overall dimensions for 800mm, 1200mm and 1500mm cabinets. The cabinets can have a single fixed front glass, in place of the twin sliding doors shown. Livery Top Insert 749 / 1149 / 1449 mm long x 50 mm wide Colour / Text Inserts Bottom Insert 754 / 1154 / 1454 mm long x 134 mm wide Max. thickness 0.75 mm If custom livery is applied to the cabinet, the insert material must be flexible, such as Formica decorative laminate or plastic sheet. Most metals cannot be flexed sufficiently for insertion in the lower position. IN 4H 08/12/15-27 - Future Products Group
Part No. 26121 Rev. D July 2017